Process and apparatus for printing assembled absorbent articles with custom graphics

ABSTRACT

The present disclosure relates to methods and apparatuses for printing graphics on absorbent articles. Printing systems according to the present disclosure may include a carrier apparatus that transports individual absorbent articles past a printing station, which prints a custom graphic on the absorbent articles. The carrier apparatus may include a hook member connected with an endless belt. The printing system may also include a pressing apparatus positioned adjacent the endless belt. During operation, an absorbent article may be positioned on a hook member, and the endless belt conveys the absorbent article in the machine direction past the printing station. As the absorbent article advances toward the printing station, the pressing apparatus compresses and flattens the absorbent article against the hook member to help provide a relatively flat, smooth surface on the absorbent article to be printed. The printing station then prints a graphic on the advancing article.

FIELD OF THE INVENTION

The present disclosure relates to apparatuses and methods for producingabsorbent products, and more particularly, methods for printing graphicson assembled, discrete absorbent articles.

BACKGROUND OF THE INVENTION

Along an assembly line, diapers and various types of other disposableabsorbent articles may be assembled by adding components to andotherwise modifying advancing, continuous webs of material. Webs ofmaterial and component parts used to manufacture diapers may include:backsheets, topsheets, absorbent cores, front and/or back ears, fastenercomponents, and various types of elastic webs and components such as legelastics, barrier leg cuff elastics, and waist elastics. In someprocesses, graphics are printed on individual components and/orcontinuous webs of material used to assemble the absorbent articles.

Some consumers may prefer purchasing absorbent articles, such asdiapers, having a number of different graphic designs printed thereonand provided in a single package. Further, some consumers may preferpurchasing diapers having customized graphics printed thereon. Variousmethods and apparatuses can be used to print different graphics on anadvancing web of material used in the manufacture of absorbent articles.However, such methods and apparatuses may provide for limited numbers ofdifferent printed graphics; graphics with relatively low quality print;and/or require relatively low print and/or manufacture speeds. Inaddition, such methods and apparatuses may also require relativelyexpensive processes and equipment and may not be very flexible inallowing a user to change the type of graphics to be printed.

As such, there remains a demand to create and supply relatively smallquantities of diapers in a single order that are printed withcustomized/personalized graphics efficiently, while at the same timemaintaining a large degree of flexibility to fill large numbers oforders.

SUMMARY OF THE INVENTION

The present disclosure relates to methods and apparatuses for printinggraphics on absorbent articles. Printing systems according to thepresent disclosure may include a carrier apparatus that transportsindividual absorbent articles past a printing station, which in turn,prints a custom graphic on the absorbent articles. The carrier apparatusmay include one or more hook members connected with an endless belt. Theprinting system may also include a pressing apparatus positionedadjacent to the endless belt. During operation, an absorbent article maybe positioned on a hook member, and the endless belt conveys theabsorbent article in the machine direction past the printing station. Asthe absorbent article advances toward the printing station, the pressingapparatus compresses and flattens the absorbent article against the hookmember to help provide a relatively flat, smooth and wrinkle-freesurface on the absorbent article to be printed. The printing stationthen prints a graphic on the advancing article.

In one form, a method may be adapted for producing customized absorbentarticles, wherein each absorbent article comprises a chassis including afirst surface and an opposing second surface, the chassis having alongitudinal axis and a lateral axis, a first end region longitudinallyopposed to a second end region, and a central region longitudinallyintermediate of the first and second end regions. The method includesthe steps of: providing a carrier including an endless belt and a hookmember, the hook member including a base member connected with a supportmember, the support member including a first surface and an opposingsecond surface, wherein the base member is connected with the endlessbelt and wherein the support member defines a distal end portion;placing the chassis of an absorbent article on the hook member such thatthe first surface of the first end region is in a facing relationshipwith the first surface of the support member, the distal end portion ofthe support member is adjacent to the central region, and the second endregion is positioned between the second surface of the support memberand the endless belt; advancing the hook member and the absorbentarticle in a machine direction; pressing the advancing absorbent articleagainst the first surface of the support member; printing a graphic onthe second surface of the advancing absorbent article; and removing theabsorbent article from the hook member.

In another form, an apparatus for printing graphics onto absorbentarticles includes: an ink jet printing device; an endless belt extendingin a machine direction adjacent to the ink jet printing device, theendless belt including a first surface and an opposing second surface; ahook member including: a base member connected with the endless belt; asupport member connected with the base member and extending in themachine direction from the base member to a distal end portion, thesupport member including a first surface and an opposing second surface,wherein the second surface of the support member faces the first surfaceof the endless belt; a plurality of rollers, each roller having an outercircumferential surface and adapted to rotate about an axis of rotationextending in a cross direction, wherein the rollers are spaced apartfrom each other along the machine direction with the outercircumferential surfaces adjacent the first surface of the endless belt.

In yet another form, a method may be adapted for producing customizeddiapers, wherein each diaper comprises a chassis including a firstsurface and an opposing second surface, the chassis having alongitudinal axis and a lateral axis, a first waist regionlongitudinally opposed to a second waist region, and a crotch regionlongitudinally intermediate of the first and second waist regions. Themethod includes the steps of: receiving an order for diapers havingcustomized graphics printed thereon; programming a printer to print thecustomized graphics; advancing a hook member in a machine direction, thehook member having a support member defining a distal end portion;positioning the diaper on the hook member such that chassis is foldedaround the support member to place the crotch region adjacent crotchregion; pressing the diaper against the support member; printing agraphic on the advancing diaper; and removing the diaper from the hookmember.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a perspective view of an absorbent article.

FIG. 2 is a partially cut away plan view of the absorbent article shownin FIG. 1.

FIG. 3 is a schematic right side view of a printing apparatus.

FIG. 4 is a schematic top side view of the printing apparatus shown inFIG. 3.

FIG. 5 is a detailed isometric view of a carrier apparatus.

FIG. 6 is a detailed side view of an absorbent article positioned on aprinting apparatus.

DETAILED DESCRIPTION OF THE INVENTION

The following explanation terms may be useful in understanding thepresent disclosure:

“Absorbent article” is used herein to refer to consumer products whoseprimary function is to absorb and retain soils and wastes. “Diaper” isused herein to refer to an absorbent article generally worn by infantsand incontinent persons about the lower torso. The term “disposable” isused herein to describe absorbent articles which generally are notintended to be laundered or otherwise restored or reused as an absorbentarticle (e.g., they are intended to be discarded after a single use andmay also be configured to be recycled, composted or otherwise disposedof in an environmentally compatible manner).

An “elastic,” “elastomer” or “elastomeric” refers to materialsexhibiting elastic properties, which include any material that uponapplication of a force to its relaxed, initial length can stretch orelongate to an elongated length more than 10% greater than its initiallength and will substantially recover back to about its initial lengthupon release of the applied force.

As used herein, the term “joined” encompasses configurations whereby anelement is directly secured to another element by affixing the elementdirectly to the other element, and configurations whereby an element isindirectly secured to another element by affixing the element tointermediate member(s) which in turn are affixed to the other element.

“Longitudinal” means a direction running substantially perpendicularfrom a waist edge to a longitudinally opposing waist edge of anabsorbent article when the article is in a flat out, uncontracted state,or from a waist edge to the bottom of the crotch, i.e. the fold line, ina bi-folded article. Directions within 45 degrees of the longitudinaldirection are considered to be “longitudinal.” “Lateral” refers to adirection running from a longitudinally extending side edge to alaterally opposing longitudinally extending side edge of an article andgenerally at a right angle to the longitudinal direction. Directionswithin 45 degrees of the lateral direction are considered to be“lateral.”

The term “substrate” is used herein to describe a material which isprimarily two-dimensional (i.e. in an XY plane) and whose thickness (ina Z direction) is relatively small (i.e. 1/10 or less) in comparison toits length (in an X direction) and width (in a Y direction).Non-limiting examples of substrates include a web, layer or layers orfibrous materials, nonwovens, films and foils such as polymeric films ormetallic foils. These materials may be used alone or may comprise two ormore layers laminated together. As such, a web is a substrate.

The term “nonwoven” refers herein to a material made from continuous(long) filaments (fibers) and/or discontinuous (short) filaments(fibers) by processes such as spunbonding, meltblowing, carding, and thelike. Nonwovens do not have a defined woven or knitted filament pattern.

The term “machine direction” (MD) is used herein to refer to thedirection of material flow through a process. In addition, relativeplacement and movement of material can be described as flowing in themachine direction through a process from upstream in the process todownstream in the process.

The term “cross direction” (CD) is used herein to refer to a directionthat is generally perpendicular to the machine direction.

The term “pant” (also referred to as “training pant”, “pre-closeddiaper”, “diaper pant”, “pant diaper”, and “pull-on diaper”) refersherein to disposable absorbent articles having a continuous perimeterwaist opening and continuous perimeter leg openings designed for infantor adult wearers. A pant can be configured with a continuous or closedwaist opening and at least one continuous, closed, leg opening prior tothe article being applied to the wearer. A pant can be preformed byvarious techniques including, but not limited to, joining togetherportions of the article using any refastenable and/or permanent closuremember (e.g., seams, heat bonds, pressure welds, adhesives, cohesivebonds, mechanical fasteners, etc.). A pant can be preformed anywherealong the circumference of the article in the waist region (e.g., sidefastened or seamed, front waist fastened or seamed, rear waist fastenedor seamed.

“Pre-fastened” refers herein to pant diapers manufactured and providedto consumers in a configuration wherein the front waist region and theback waist region are fastened or connected to each other as packaged,prior to being applied to the wearer. As such pant diapers may have acontinuous perimeter waist opening and continuous perimeter leg openingsdesigned for infant or adult wearers. As discussed in more detail below,a diaper pant can be preformed by various techniques including, but notlimited to, joining together portions of the diaper using refastenableand/or permanent closure members (e.g., seams, heat bonds, pressurewelds, adhesives, cohesive bonds, mechanical fasteners, etc.). Inaddition, pant diapers can be preformed anywhere along the circumferenceof the waist region (e.g., side fastened or connected, front waistfastened or connected, rear waist fastened or connected).

The term “body facing surface” refers to surfaces of absorbent articlesand/or components thereof which face a wearer's body when the absorbentarticles are worn, and the term “garment facing surface” refers tosurfaces of absorbent articles and/or components thereof that face awayfrom a wearer's body when the absorbent articles are worn. Absorbentarticles and components thereof, including the topsheet, backsheet,absorbent core, and any individual materials of their components, have abody facing surface and a garment facing surface.

The term “graphic” refers to images or designs that are constituted by afigure (e.g., a line(s)), a symbol or character, a color difference ortransition of at least two colors, or the like. A graphic may include anaesthetic image or design that can provide certain benefit(s) when anabsorbent article is viewed. A graphic may be in the form of aphotographic image. A graphic may also be in the form of a 1-dimensional(1-D) or 2-dimensional (2-D) bar code or a quick response (QR) bar code.A graphic design is determined by, for example, the color(s) used in thegraphic (individual pure ink colors as well as built process colors),the sizes of the entire graphic (or components of the graphic), thepositions of the graphic (or components of the graphic), the movementsof the graphic (or components of the graphic), the geometrical shapes ofthe graphic (or components of the graphics), the number of colors in thegraphic, the variations of the color combinations in the graphic, thenumber of graphics printed, the disappearance of color(s) in thegraphic, and the contents of text messages in the graphic.

“Different in terms of graphic design” means that graphics are intendedto be different when viewed by users or consumers with normalattentions. Thus, two graphics having a graphic difference(s) which areunintentionally caused due to a problem(s) or an error(s) in amanufacture process, for example, are not different from each other interms of graphic design.

“Standard” or “standardized” refers to graphics, products, and/orarticles that have the same aesthetic appearance without intending to bedifferent from each other.

The term “custom” or “customized” refers to graphics, products, and/orarticles that are changed to suit a small demographic, region,purchaser, customer, or the like. Custom graphics may be selected from aset of graphics. For example, custom graphics may include animaldepictions selected from groups of animals, such as farm animals, seacreatures, birds, and the like. In other examples, custom graphics mayinclude nursery rhymes and the like. In one scenario, custom products orarticles may be created by a purchaser of such products or articleswherein the purchaser selects graphics for the articles or products froma set of graphics offered by a manufacturer of such articles orproducts. Custom graphics may also include “personalized” graphics,which may be graphics created for a particular purchaser. For example,personalized graphics may include a person's name alone or incombination with a design.

Aspects of the present disclosure relates to methods and apparatuses formanufacturing absorbent articles, and more particularly, apparatuses andmethods for printing graphics on assembled, discrete individualabsorbent articles. It is to be appreciated that various types ofgraphics may be printed in accordance with the methods and apparatusesherein, such as for example, standardized graphics, custom graphics, andpersonalized graphics. As discussed in more detail below, printingsystems according to the present disclosure may include a carrierapparatus that transports individual absorbent articles in a machinedirection past a printing station, which in turn, prints a customgraphic on the absorbent articles. The carrier apparatus may include oneor more hook members connected with an endless belt. Each hook membermay include a base member connected with the endless belt; and a supportmember connected with the base member. The support member may extend inthe machine direction from the base member to a distal end portion. Theprinting system may also include a pressing apparatus having a pluralityof rollers spaced apart from each other along the machine direction andpositioned adjacent the endless belt. During operation, an absorbentarticle may be positioned on a hook member, and the endless belt conveysthe absorbent article in the machine direction past the printingstation. As the absorbent article advances toward the printing station,the rollers of the pressing apparatus compress and flatten the absorbentarticle against the support member to help provide a relatively flat,smooth, wrinkle-free surface on the absorbent article to be printed. Agraphic is then printed on the absorbent article while advancing pastthe printing station. Once printed, the absorbent article may be removedfrom the hook member.

It is to be appreciated that although the methods and apparatuses hereinmay be configured to print various types of products, the methods andapparatuses herein are discussed below in the context of manufacturingabsorbent articles. In particular, the methods and apparatuses arediscussed in the context of printing diapers during production. For thepurposes of a specific illustration, FIGS. 1 and 2 shows one example ofa disposable absorbent article 150 in the form of a custom diaper 170which may be printed in accordance with the apparatuses and methodsherein. FIG. 2 is a plan view of the diaper 170 including a chassis 172shown in a flat, unfolded condition, with the portion of the diaper thatfaces away from a wearer oriented towards the viewer. A portion of thechassis structure is cut-away in FIG. 2 to more clearly show theconstruction of and various features that may be included in embodimentsof the diaper.

As shown in FIGS. 1 and 2, the diaper 170 includes a 172 chassis havinga first ear 174, a second ear 176, a third ear 178, and a fourth ear180. To provide a frame of reference for the present discussion, thechassis 172 is shown with a longitudinal axis 182 and a lateral axis184. The chassis 172 is shown as having a first end region 186, a secondend region 188, and a central region 190 disposed intermediate the firstand second end regions. The first end region may also be referred to asa first waist region 186; the second end region may also be referred toas a second waist region 188; and the central region may also bereferred to as a crotch region 190. The periphery of the diaper isdefined by a pair of longitudinally extending side edges 192, 194; afirst outer edge 196 extending laterally adjacent the first waist region186; and a second outer edge 198 extending laterally adjacent the secondwaist region 188. As shown in FIG. 1, the diaper 170 has a waist opening200 and two leg openings 202. The diaper 170 may also be provided in theform of a pant-type diaper or may alternatively be provided with are-closable fastening system, which may include fastener elements invarious locations to help secure the diaper in position on the wearer.For example, fastener elements may be located on the ears and may beadapted to releasably connect with one or more corresponding fasteningelements located in the first or second waist regions.

As shown in FIGS. 1 and 2, the chassis includes an inner, body facingsurface 204, and an outer, garment facing surface 206. As shown in FIG.2, the chassis 172 may include an outer covering layer 208 including atopsheet 210 and a backsheet 212. An absorbent core 214 may be disposedbetween a portion of the topsheet 210 and the backsheet 212. It is to beappreciated that any one or more of the regions of the chassis may bestretchable and may include various types of elastomeric materialsand/or laminates. As such, the diaper may be configured to adapt to aspecific wearer's anatomy upon application and to maintain coordinationwith the wearer's anatomy during wear.

Embodiments of the diaper may also include pockets for receiving andcontaining waste, spacers which provide voids for waste, barriers forlimiting the movement of waste in the article, compartments or voidswhich accept and contain waste materials deposited in the diaper, andthe like, or any combinations thereof. Examples of pockets and spacersfor use in absorbent products are described in U.S. Pat. Nos. 5,514,121;5,171,236; 5,306,266; 5,397,318; 5,540,671; and PCT Application WO93/25172; which are all hereby incorporated by reference herein.Examples of compartments or voids are disclosed in U.S. Pat. Nos.4,968,312; 4,990,147; 5,062,840; 6,482,191; and 5,269,755, which are allhereby incorporated by reference herein. Examples of suitable transversebarriers are described in U.S. Pat. Nos. 5,554,142 and 5,653,703; andPCT Patent Publication WO 94/14395, which are all hereby incorporated byreference herein. All of the above-cited references are herebyincorporated by reference herein. In addition to or in place of thevoids, pockets and barriers, described above, embodiments of theabsorbent article may also include a waste management element capable ofeffectively and efficiently accepting, storing and/or immobilizingviscous fluid bodily waste, such as runny feces, such as described inU.S. Pat. No. 6,010,491, which is hereby incorporated by referenceherein.

As previously mentioned, the chassis 172 may include the backsheet 212,shown for example, in FIG. 2. In some embodiments, the backsheet isconfigured to prevent exudates absorbed and contained within the chassisfrom soiling articles that may contact the diaper, such as bedsheets andundergarments. Some embodiments of the backsheet may be fluid permeable,while other embodiments may be impervious to liquids (e.g., urine) andcomprises a thin plastic film. Some backsheet films may include thosemanufactured by Tredegar Industries Inc. of Terre Haute, Ind. and soldunder the trade names X15306, X10962, and X10964. Other backsheetmaterials may include breathable materials that permit vapors to escapefrom the diaper while still preventing exudates from passing through thebacksheet. Exemplary breathable materials may include materials such aswoven webs, nonwoven webs, composite materials such as film-coatednonwoven webs, and microporous films. Suitable breathable compositematerials are described in greater detail in PCT Application No. WO95/16746, published on Jun. 22, 1995 in the name of E. I. DuPont andU.S. Pat. No. 5,865,823, both of which are hereby incorporated byreference herein. Other breathable backsheets including nonwoven websand apertured formed films are described in U.S. Pat. Nos. 5,571,096 and6,573,423, which are all hereby incorporated by reference herein.

The backsheet 212 may be formed by only one sheet (or layer) materialsuch as a breathable (or microporous) film material or a non-breathable(or non-microporous) film material. In some embodiments, the backsheetmay be formed by two (or more) sheet (or layer) materials which mayinclude a non-breathable (or breathable) film material and a nonwovenouter cover material. In some embodiments, the backsheet may be formedby a laminate of two sheet (or layer) materials joined together, forexample, the backsheet may include a non-breathable film material and anonwoven material which is joined to the garment facing surface of thefilm material to provide a cloth-like and/or garment-like feel. Inaccordance with the discussion below, graphics 136 may be printeddirectly on the backsheet 212. The diaper 170 shown in FIGS. 1 and 2includes graphics 136 in the form of standard graphics 138 and customgraphics 140. The standard graphics 138 shown may be identical on eachdiaper that is printed, and are illustrated in the form of a curvedline. It is to be appreciated that the illustrated standard graphics 138are shown as an example, and various different types of graphics may beused. In addition, the custom graphics 140 are shown in the form of afarm animal (e.g., a pig) and a person's name. It is also to beappreciated that the illustrated custom graphics are examples, and canbe printed in various other forms. In addition, the custom graphics canbe identical or different on each printed diaper.

As with the backsheet 212, graphics 136 may also be printed on thetopsheet 210. All or at least a portion of the topsheet may be liquidpervious, permitting liquid to readily penetrate therethrough. As such,the topsheet may be manufactured from a wide range of materials, such asporous foams; reticulated foams; apertured nonwovens or plastic films;or woven or nonwoven webs of natural fibers (e.g., wood or cottonfibers), synthetic fibers (e.g., polyester or polypropylene fibers), ora combination of natural and synthetic fibers. One example of a topsheetincluding a web of staple length polypropylene fibers is manufactured byVeratec, Inc., a Division of International Paper Company, of Walpole,Mass. under the designation P-8. Examples of formed film topsheets aredescribed in U.S. Pat. Nos. 3,929,135; 4,324,246; 4,342,314; 4,463,045;and 5,006,394, all of which are hereby incorporated by reference herein.Other topsheets may be made in accordance with U.S. Pat. Nos. 4,609,518and 4,629,643, both of which are hereby incorporated by referenceherein.

In some embodiments, the topsheet is made of a hydrophobic material oris treated to be hydrophobic in order to isolate the wearer's skin fromliquids contained in the absorbent core. If the topsheet is made of ahydrophobic material, at least the upper surface of the topsheet may betreated to be hydrophilic so that liquids will transfer through thetopsheet more rapidly. The topsheet can be rendered hydrophilic bytreating it with a surfactant or by incorporating a surfactant into thetopsheet. A more detailed discussion of such a treatment andhydrophilicity is contained in U.S. Pat. Nos. 4,988,344 and 4,988,345,all of which are hereby incorporated by reference herein. A moredetailed discussion of some methods for incorporating surfactant in thetopsheet can be found in U.S. Statutory Invention Registration No.H1670, which was published on Jul. 1, 1997, in the names of Aziz et al.,all of which are hereby incorporated by reference herein. In someembodiments, the topsheet 210 may include an apertured web or film thatis hydrophobic. This may be accomplished by eliminating thehydrophilizing treatment step from the production process and/orapplying a hydrophobic treatment to the topsheet, such as apolytetrafluoroethylene compound like SCOTCHGUARD or a hydrophobiclotion composition, as described below. A more detailed discussion ofvarious apertured topsheets can be found in U.S. Pat. Nos. 5,342,338;5,941,864; 6,010,491; and 6,414,215, all of which are herebyincorporated by referenced herein.

The absorbent core 214 may include components such as an acquisitionlayer and absorbent material that is generally compressible,conformable, non-irritating to the wearer's skin, and capable ofabsorbing and retaining liquids such as urine and other body exudates.The absorbent core can also be manufactured in a wide variety of sizesand shapes (e.g., rectangular, hourglass, T-shaped, asymmetric, etc.).The absorbent core may also include a wide variety of liquid-absorbentmaterials commonly used in disposable diapers and other absorbentarticles. In one example, the absorbent core includes comminuted woodpulp, which is generally referred to as airfelt. Examples of otherabsorbent materials include creped cellulose wadding; meltblownpolymers, including coform; chemically stiffened, modified orcross-linked cellulosic fibers; tissue, including tissue wraps andtissue laminates; absorbent foams; absorbent sponges; superabsorbentpolymers; absorbent gelling materials; or any other known absorbentmaterial or combinations of materials.

It is to be appreciated that the configuration and construction of theabsorbent core may be varied (e.g., the absorbent core(s) or otherabsorbent structure(s) may have varying caliper zones, a hydrophilicgradient, a superabsorbent gradient, or lower average density and loweraverage basis weight acquisition zones; or may comprise one or morelayers or structures). Exemplary absorbent structures are described inU.S. Pat. Nos. 4,610,678; 4,673,402; and 4,834,735; 4,888,231;5,137,537; 5,147,345; 5,342,338; 5,260,345; 5,387,207; and 5,650,222,all of which are hereby incorporated by reference herein.

The absorbent core may also have a multiple layered construction. A moredetailed discussion of various types of multi-layered absorbent corescan be found in U.S. Pat. Publication Nos. 2004/0162536A1 and2004/0167486A1; U.S. Pat. Nos. 5,669,894; 6,441,266; 5,562,646; EuropeanPat. No. EP0565606B1; PCT Publication No. WO 2006/015141, which are allhereby incorporated by reference herein. In some embodiments, theabsorbent article includes an absorbent core that is stretchable. Insuch a configuration, the absorbent core may be adapted to extend alongwith other materials of the chassis in longitudinal and/or lateraldirections. The absorbent core can also be connected with the othercomponents of the chassis various ways. For example, the diaper mayinclude a “floating core” configuration or a “bucket” configurationwherein the diaper includes an anchoring system that can be configuredto collect forces tending to move the article on the wearer. Such ananchoring system can also be configured to anchor itself to a body of awearer by contacting various parts of the body. In this way, theanchoring system can balance the collected moving forces with holdingforces obtained from the anchoring. By balancing the collected movingforces with the obtained holding forces, the anchoring system can atleast assist in holding the disposable wearable absorbent article inplace on a wearer.

The diapers according to the present disclosure can also include otherfeatures such as elastically extensible side panels. The side panels maybe joined at seams to form the waist opening and the leg openings. Thediapers may also includes leg elastics 216, such as shown in FIG. 2, andan elastic waist region to enhance the fits around the legs and waist ofthe wearer. Example leg elastic and leg cuff embodiments are disclosedin, for example, U.S. Pat. Nos. 4,695,278 and 4,795,454.

In addition to the backsheet and topsheet, graphics may also be printedon other components used to construct the fastening elements on thediaper, such as for example, a landing zone. Depending on the particularconfiguration, it is to be appreciated that various types of fasteningelements may be used with the diaper. In one example, the fasteningelements include hook & loop fasteners, such as those available from 3Mor Velcro Industries. In other examples, the fastening elements includeadhesives and/or tape tabs, while others are configured as amacrofastener or hook (e.g., a MACRO or “button-like” fastener). Someexemplary fastening elements and systems are disclosed in U.S. Pat. Nos.3,848,594; 4,662,875; 4,846,815; 4,894,060; 4,946,527; 5,151,092; and5,221,274, which are all hereby incorporated by reference herein.Additional examples of fasteners and/or fastening elements are discussedin U.S. Pat. Nos. 6,482,191; 6,251,097; and 6,432,098, which are allhereby incorporated by reference herein. Other fastening systems aredescribed in more detail in U.S. Pat. Nos. 5,595,567; 5,624,427;5,735,840; and 5,928,212, which are all hereby incorporated by referenceherein. The fastening system may also provide a means for holding thearticle in a disposal configuration as disclosed in U.S. Pat. No.4,963,140, which is hereby incorporated by reference herein.

Components of the disposable absorbent article (i.e., diaper, disposablepant, adult incontinence article, sanitary napkin, pantiliner, etc.)described in this specification can at least partially be comprised ofbio-sourced content as described in US 2007/0219521A1 Hird et alpublished on Sep. 20, 2007, US 2011/0139658A1 Hird et al published onJun. 16, 2011, US 2011/0139657A1 Hird et al published on Jun. 16, 2011,US 2011/0152812A1 Hird et al published on Jun. 23, 2011, US2011/0139662A1 Hird et al published on Jun. 16, 2011, and US2011/0139659A1 Hird et al published on Jun. 16, 2011. These componentsinclude, but are not limited to, topsheet nonwovens, backsheet films,backsheet nonwovens, side panel nonwovens, barrier leg cuff nonwovens,super absorbent, nonwoven acquisition layers, core wrap nonwovens,adhesives, fastener hooks, and fastener landing zone nonwovens and filmbases.

In at least one exemplary configuration, a disposable absorbent articlecomponent comprises a bio-based content value from about 10% to about100% using ASTM D6866-10, method B, in another embodiment, from about25% to about 75%, and in yet another embodiment, from about 50% to about60% using ASTM D6866-10, method B.

In order to apply the methodology of ASTM D6866-10 to determine thebio-based content of any disposable absorbent article component, arepresentative sample of the disposable absorbent article component mustbe obtained for testing. In at least one embodiment, the disposableabsorbent article component can be ground into particulates less thanabout 20 mesh using known grinding methods (e.g., Wiley® mill), and arepresentative sample of suitable mass taken from the randomly mixedparticles.

As previously mentioned, apparatuses and methods according to thepresent disclosure may be configured for printing graphics on assembled,discrete individual absorbent articles. FIGS. 3 to 5 show an exampleprinting apparatus 300 adapted to print graphics 136 on fully assembled,discrete, individual diapers 170. In one scenario, fully assembleddiapers 170 may be removed from an assembly line and/or a package andmanually placed on the printing apparatus 300. In turn, the printingapparatus may be configured to print one more graphics 136, such asstandard graphics 138 and/or custom graphics 140, on the diapers 170.The printing apparatus 300 may include a carrier apparatus 302, apressing apparatus 304, and a printing station 306. As discussed in moredetail below, the carrier apparatus 302 may convey diapers 170 in amachine direction MD past the printing station 306, which in turn,prints a graphic 136 on the diaper 170. As the diapers move in themachine direction MD, the pressing apparatus 304 compresses and flattensportions of the diapers 170 against the carrier apparatus 302 to helpprovide a relatively smooth, flat surface on the diapers 170 to beprinted. The diapers 170 may be removed from the carrier apparatus 302after being printed.

With continued reference to FIGS. 3 to 5, the carrier apparatus 302 mayinclude one more hook members 308 connected with an endless belt 310surrounding a plurality or rollers 312. The conveyor rollers 312 mayinclude a drive roller 312 a and one or more idler rollers 312 b. Asdiscussed in more detail below, diapers 170 may be positioned on thehook members 308, and the endless belt 310 conveys the hook members 308and diapers 170 positioned thereon in the machine direction MD past theprinting station 306. As shown in FIGS. 3 to 5, the endless belt 308 mayinclude a first surface 314 and an opposing second surface 316. Eachconveyor roller 312 may each include an outer circumferential surface318 and may be adapted to rotate about an axis of rotation 320. Thesecond surface 316 of the endless belt 310 may be positioned in contactwith the outer circumferential surfaces 318 of the conveyor rollers 312.As shown in FIG. 6, the carrier apparatus 302 may also include a skidplate 322 to help support the endless belt 310 in a region adjacent theprint station 306. More particularly, the skid plate 322 may extend inthe machine direction MD and the cross direction CD and may be in directcontact with the second surface 316 of the endless belt 310. As such,the skid plate 322 may help prevent and/or reduce deflection of theendless belt 310 away from the printing station 306 while the diapers170 positioned on hook members 308 advance in the machine direction MDpast the printing station 306. It is to be appreciated the printingapparatus 300 may be configured the hook members 308 and diapers 170positioned thereon at various speeds. For example, in someconfigurations, the hook members 308 may advance at speeds from about0.365 to about 1.25 meters per second. In some configurations, the speedmay be higher than 1.25 meters per second. It is also to be appreciatedthat the endless belt may define various different widths, B_(w), in thecross direction CD. For example, in some configurations, the width,B_(w), may be about 152.4 mm.

As shown in FIGS. 3 to 5, each hook member 308 may include a proximalend portion 324 connected with the first surface 314 of the endless belt310. In some configurations, the hook member 308 may include a basemember 328 connected with a support member 330. It is to be appreciatedthat the base member 328 and the support member 330 may be configured asseparate parts connected with the each other or may be integrally formedtogether as a single piece. As shown in FIG. 5, the base member 328 mayextend from the proximal end portion 324 to a second end portion 332that is connected with a first end portion 334 of the support member330. From the first end portion 334, the support member 330 extends tothe distal end portion 326. The support member 330 may include a firstsurface 336 and an opposing second surface 338 that define a planarshape having a cross directional width, W, and a machine directionlength, L. In addition, adjacent hook members 330 may be separated fromeach other by a distance, D_(sep). It is to be appreciated that theapparatus may be configured with various different widths, W; lengths,L, and separation distances, D_(sep). For example, in someconfigurations, the length L may be about 230 mm and the separationdistance D_(sep) may be about 70 mm. The second surface 338 of thesupport member 330 may be in a facing relationship with the firstsurface 314 of the endless belt 310. As shown in FIGS. 3 to 5, the hookmember 308 may be connected with the endless belt 310 such that the basemember 328 extends away from the first surface 314 of the endless belt310 and the support member 330 may extend in the machine direction MD tothe distal end portion 326. As such, the second surface 338 of thesupport member 330 may be separated by a distance, H, from the firstsurface 314 of the endless belt 310. It is to be appreciated that thehook members 308 may be connected with the endless belt in various ways,such as for example, adhesives, welding, and/or fasteners. In someembodiments, the hook members may be formed integrally with the endlessbelt.

As previously mentioned, the diapers 170 may be positioned on the hookmembers 308 before being conveyed by the endless belt 310 past theprinting station 306. FIG. 6 shows a detailed side view of two diapers170 positioned on hook members 308. More particularly, the diapers 170may be positioned such that the outer, garment facing surface 206 of thefirst waist region 186 is in a facing relationship with the printingstation 306. And the inner, body facing surface 204 of the first waistregion 186 of the diaper 170 is in a facing relationship and in directcontact with the first surface 336 of the support member 330. The diaper170 may be folded around the support member 330 such that the distal endportion 326 of the support member is adjacent to the inner, body facingsurface 204 of the crotch region 190 of the diaper 170. In addition, theinner, body facing surface 204 of the second waist region 188 may be ina facing relationship with the second surface 338 of the support member330, and the outer, garment facing surface 206 of the second waistregion 188 is in a facing relationship with the first surface 314 of theendless belt 310.

It is to be appreciated the diaper 170 can be positioned on the hookmember 308 in various other orientations than what is shown anddescribed with respect to FIG. 6. For example, the diaper 170 may bepositioned on the hook members such that the second waist region 188 islocated between the first surface 336 of the support member 330 and theprinting station 306. In another orientation, the outer, garment facingsurface 206 of the diaper 170 may be positioned in a facing relationshipwith the first surface 336 and the second surface 338 of the supportmember 330.

As previously mentioned, the printing apparatus 300 may also include apressing apparatus 304 that compresses the diaper 170 against the hookmember 308 as the diaper is conveyed in the machine direction MD pastthe printing station 306. As shown in FIGS. 3, 4, and 6, the pressingapparatus 304 may include a plurality of rollers 340 rotatably connectedwith a frame 342. Each roller 340 may include a cylindrically-shapedouter circumferential surface 344. The rollers 340 may be spaced apartfrom each other along the machine direction MD and each roller 340 maybe adapted to rotate about an axis of rotation 346 extending in a crossdirection CD. The rollers 340 may be supported adjacent the firstsurface 314 of the endless belt 310 such that the hook members 308 areadvanced in the machine direction between the endless belt 310 and theouter circumferential surfaces 344 of the rollers 340. The frame 342 maysupport the rollers 340 to as to define a minimum distance, d, betweenthe outer circumferential surfaces 344 of the rollers 340 and the firstsurfaces 326 of support members 330. In some configurations, thedistance, d, may be the same distance between all or some rollers 340and support members 330. In some configurations, the distance, d,between rollers 340 and the support members 330 may progressivelydecrease along the machine direction MD. As shown in FIG. 6, as a diaper170 positioned on a hook member 308 advances in the machine directionMD, the outer circumferential surfaces 344 of the rollers 340 press thediaper against first surface 336 of the support member 336. As such, therollers 340 compress and help flatten the diaper 170 against the supportmember to provide a relatively smooth, flat surface in preparation forprinting at the printing station 306. It is to be appreciated that somepressing mechanisms may be configured with an endless belt surroundingthe rollers 340. In some configurations, the pressing mechanism maycomprise a smooth, stationary skid plate.

In some configurations, the printing apparatus 300 may be configuredwith one or more various features that allow the distance, d, betweenthe outer circumferential surfaces 344 of the rollers 340 and the firstsurfaces 326 of support members 330 to be automatically or manuallyadjusted. For example, the frame 342 may include adjustable supportmembers 343 adapted to allow the position of the frame 342 relative tothe endless belt 310 and/or hook members 308 to be adjusted. In someconfigurations, the positions of the hook members 308 relative to theendless belt 310 may be adjustable. In some configurations, thepositions of the support members 330 relative to the base members 328may be adjustable.

As previously mentioned, the endless belt 310 advances the hook members308 and diapers 170 positioned thereon in the machine direction MD pastthe printing station 306, which in turn, prints graphics 136 on thediapers 170. It is to be appreciated that the printing station 306 maybe configured in various ways and may include various types of printingaccessories. For example, in some embodiments, the printing station 306may include a printer 348 in the form of an ink-jet printer. Ink-jetprinting is a non-impact dot-matrix printing technology in whichdroplets of ink are jetted from a small aperture directly to a specifiedposition on a media to create a graphic. Two examples of inkjettechnologies include thermal bubble or bubble jet and piezoelectric.Thermal bubble uses heat to apply to the ink, while piezoelectric uses acrystal and an electric charge to apply the ink. In some configurations,the printing station 306 may include a corona treater 350, which may bepositioned upstream of the printer 348. The corona treater 350 may beconfigured to increase the surface energy of the surface of the diaper170 to be printed. In some embodiments, the corona treater 350 may beconfigured to increase the surface energy of the outer surface of adiaper to about 42 dynes/cm. In some configurations, the printingstation 306 may also include an ink curing apparatus 352. In someconfigurations, the ink curing apparatus 352 may be in the form of anultraviolet (UV) light source 352 that may include one or moreultraviolet (UV) lamps, which may be positioned downstream of theprinter 348 to help cure inks deposited onto the diaper 170 from theprinter 348 to form the graphics 136. In some configurations, the inkcuring apparatus 352 may also include an infrared (IR) dryer lightsource that may include one or more infrared (IR) lamps, which may bepositioned downstream of the printer 348 to help dry water-based orsolvent-based inks deposited onto the diaper 170 from the printer 348 toform the graphics 136. In some configurations, the ink curing apparatus352 may include an electron beam (EB or e-beam) generator that mayinclude one or more e-beam electrodes, which may be positioneddownstream of the printer 348 to help cure inks deposited onto thediaper 170 from the printer 348 to form the graphics 136.

In some configurations, the printing station 306 may be adapted tointerface with a computer that allows an operator to manually programthe type of graphics to be printed. For example, the printing station306 may be configured with various features, such as available on theXD070 Multi-Color Industrial Ink Jet unit available from Pad PrintMachinery of Vermont. In some configurations, the printing station 306may be configured to interface with other computerized systems and/ornetworks that may automatically program or command the printing station306 to print various graphics based on various input, such as salesorders from customers.

To provide additional context to the above discussion, the followingprovides a description of an example implementation of the printingmethods and apparatuses herein with reference to various elementsidentified in FIGS. 1 to 6. In a method of operation, one or more ordersfor diapers having graphics 136 may be received. In response to suchorders, the printing station 306 may be programmed to print the graphics136 specified in the order or orders, such as standard graphics 138and/or customized graphics 140. In one scenario, an order may requestpersonalized graphics to be printed on diapers 170 available forpurchase in various packaged quantities offered by a diapermanufacturer. As such, fully assembled diapers may be removed from sucha package, printed with the requested graphics, repackaged, and providedto a consumer in fulfillment of the order.

With continued reference to FIGS. 1 to 6, upon receipt of an order forprinted diapers, fully assembled or completely manufactured, individualdiapers 170 may be taken from an assembly line or unpacked from apackage and positioned on the carrier apparatus 302. More particularly,each diaper 170 may be positioned on a respective hook member 308. Forexample, an order may specify custom graphics 140, such as personalizedgraphics, to be printed on the backsheets 212 of diapers 170. Anoperator may place individual diapers 170 on the hook members 308 suchthat the inner, body facing surface 204 or topsheet 210 of either thefirst waist region 186 or second waist region 188 of the diaper 170 isin a facing relationship with the first surface 336 of the supportmember 330. The diaper 170 may be folded around the support member 330such that the crotch portion 190 is adjacent the distal end portion 326of the hook member 308. And the opposing waist region of the diaper 170may be positioned between the second surface 338 of the support member330 and the first surface 314 of the endless belt 310.

Once the diaper 170 is positioned on the hook member 308, the endlessbelt 310 may advance the diaper 170 in the machine direction MD towardthe printing station 306. While advancing in the machine direction MD,the rollers 340 contact the outer, garment facing surface 206 orbacksheet 212 of the diaper 170 and press the diaper against the firstsurface 336 of the support member 330. The compression of the diapers170 between the support member 330 and the rollers 340 helps to flattenand smooth out a portion of the backsheet 212 to be printed at theprinting station 306. As the diaper 170 continues advance in the machinedirection MD, the corona treater 350 may act on the backsheet 212 toincrease the surface energy of the backsheet material. From the coronatreater 350, the diaper 170 advances in the machine direction MD pastthe printer 348 to be printed with the graphics 136 on the backsheet 212in accordance with the received order. From the printer 348, the diaper170 may advance in the machine direction MD past the ink curingapparatus 352 to cure the ink deposited on the backsheet 212 from theprinter 348 to create the graphic 136. An operator may then remove thediaper 170 from the hook member 308 and packaged to be provided to acustomer in fulfillment of the received order.

As discussed above, diapers may be positioned on hook members in variousways so as to print graphics on various components of the diapers. Forexample, the diapers may be positioned on the hook members to print thetopsheets, backsheets, and/or fastening components. The diapers may alsobe advanced through the printing apparatus more than once in order toprint graphics on additional locations and/or components. For example,diapers may be advanced through the printing apparatus to print graphicson first and second waist regions and/or both the topsheets andbacksheets.

Although the present disclosure is provided in the context ofmanufacturing absorbent articles, and diapers in particular, it is to beappreciated that the systems and methods disclosed herein may be appliedto the manufacture of various types of articles and products,individually or wound roll, involving various different types ofsubstrates and/or components. Examples of other products may includeabsorbent articles for inanimate surfaces such as consumer productswhose primary function is to absorb and retain soils and wastes that maybe solid or liquid and which are removed from inanimate surfaces such asfloors, objects, furniture and the like. Non-limiting examples ofabsorbent articles for inanimate surfaces include dusting sheets,pre-moistened wipes or pads, paper towels, dryer sheets. Additionalexamples of products include absorbent articles for animate surfaceswhose primary function is to absorb and contain body exudates and, morespecifically, devices which are placed against or in proximity to thebody of the user to absorb and contain the various exudates dischargedfrom the body. Non-limiting examples of incontinent absorbent articlesinclude diapers, adult incontinence briefs and undergarments, femininehygiene articles such as sanitary pads, panty liners, absorbent inserts,and the like, toilet paper, tissue paper, disposable kitchen towels,disposable napkins, facial wipes or clothes, toilet training wipes.Still other examples of products include packaging components andsubstrates and/or containers.

It is also to be appreciated that the printing apparatuses and methodsdisclosed herein may be adapted to include various additional featuresand configurations. For example, the endless belt and/or hook membersmay be configured to operate in conjunction with vacuum systems thathelp hold the absorbent articles in position during printing. In anotherexample, a vacuum system may be utilized to hold the absorbent articlesin position without the need for hook members. In another example, asopposed to having an endless belt, the carrier apparatus may beconfigured with one or more linear motors to advance the hook memberspast the print device. Such linear motor technology and carrierconfigurations that could be adapted to advance the hook members aredisclosed in U.S. Pat. Nos. 7,134,258 and 8,100,253. In yet otherconfigurations, the printing apparatus may be configured such that thediaper is held stationary and the printing station moves adjacent thediapers while printing the graphics. The printing apparatuses herein mayalso be adapted to include vision systems utilizing cameras that mayverify printing quality, color authenticity, color intensity,text/graphic location, and printing defects. Systems that count thenumber of printed diapers and automatically performs packing operationsof such printed diapers may also be adapted to work in conjunction withthe printing apparatuses and methods herein.

The dimensions and values disclosed herein are not to be understood asbeing strictly limited to the exact numerical values recited. Instead,unless otherwise specified, each such dimension is intended to mean boththe recited value and a functionally equivalent range surrounding thatvalue. For example, a dimension disclosed as “40 mm” is intended to mean“about 40 mm.”

Every document cited herein, including any cross referenced or relatedpatent or application, is hereby incorporated herein by reference in itsentirety unless expressly excluded or otherwise limited. The citation ofany document is not an admission that it is prior art with respect toany invention disclosed or claimed herein or that it alone, or in anycombination with any other reference or references, teaches, suggests ordiscloses any such invention. Further, to the extent that any meaning ordefinition of a term in this document conflicts with any meaning ordefinition of the same term in a document incorporated by reference, themeaning or definition assigned to that term in this document shallgovern.

While particular embodiments of the present invention have beenillustrated and described, it would be obvious to those skilled in theart that various other changes and modifications can be made withoutdeparting from the spirit and scope of the invention. It is thereforeintended to cover in the appended claims all such changes andmodifications that are within the scope of this invention.

What is claimed is:
 1. A method for producing customized absorbentarticles, each absorbent article comprising a chassis including a firstsurface and an opposing second surface, the chassis having alongitudinal axis and a lateral axis, a first end region longitudinallyopposed to a second end region, and a central region longitudinallyintermediate of the first and second end regions, the method comprisingthe steps of: providing a carrier including an endless belt and a hookmember, the hook member including a base member connected with a supportmember, the support member including a first surface and an opposingsecond surface, wherein the base member is connected with the endlessbelt and wherein the support member defines a distal end portion;placing the chassis of an absorbent article on the hook member such thatthe first surface of the first end region is in a facing relationshipwith the first surface of the support member, the distal end portion ofthe support member is adjacent the central region, and the second endregion is positioned between the second surface of the support memberand the endless belt; advancing the hook member and the absorbentarticle in a machine direction; pressing the advancing absorbent articleagainst the first surface of the support member; increasing the surfaceenergy of the second surface of the chassis; printing a graphic on thesecond surface of the advancing absorbent article; and removing theabsorbent article from the hook member.
 2. The method of claim 1,wherein the compressing step further comprises advancing the first endregion in the machine direction between a plurality of rollers and thesupport member.
 3. The method of claim 1, wherein the first end regionis a first waist region, the second end region is a second waist region,and the central region is a crotch region.
 4. The method of claim 3,wherein the first waist region comprises a front waist region.
 5. Themethod of claim 3, wherein the second surface of the chassis comprises agarment facing surface.
 6. The method of claim 1, wherein the secondsurface of the chassis is defined by a backsheet.
 7. The method of claim1, wherein the step of increasing the surface energy further comprisesadvancing the chassis in the machine direction past a corona treater. 8.The method of claim 1, wherein the step of printing further comprisingdepositing ink onto the second surface of the chassis from an ink jetprinter.
 9. The method of claim 8, further comprising the step of curingthe ink.
 10. The method of claim 9, wherein the step of curing furthercomprises advancing the chassis past an ink curing apparatus selectedfrom the group of consisting of: an ultra violet light source and anelectron beam generator.
 11. An apparatus for printing graphics ontoabsorbent articles, the apparatus comprising: an ink jet printingdevice; an endless belt extending in a machine direction adjacent theink jet printing device, the endless belt including a first surface andan opposing second surface; a hook member including: a base memberconnected with the endless belt; a support member connected with thebase member and extending in the machine direction from the base memberto a distal end portion, the support member including a first surfaceand an opposing second surface, wherein the second surface of thesupport member faces the first surface of the endless belt; a pluralityof rollers, each roller having an outer circumferential surface andadapted to rotate about an axis of rotation extending in a crossdirection, wherein the rollers are spaced apart from each other alongthe machine direction with the outer circumferential surfaces adjacentthe first surface of the endless belt, and a minimum distance, d,between the outer circumferential surface of each roller and the firstsurface of the support member, wherein the distance, d, is the same formore than one roller.
 12. The apparatus of claim 11, further comprisinga frame, wherein the rollers are rotatably supported by the frame. 13.The apparatus of claim 11, wherein the distance, d, is variable.
 14. Theapparatus of claim 11, further comprising an ink curing apparatus. 15.An apparatus for printing graphics onto absorbent articles, theapparatus comprising: an ink jet printing device; an endless beltextending in a machine direction adjacent the ink jet printing device,the endless belt including a first surface and an opposing secondsurface; a hook member including: a base member connected with theendless belt; a support member connected with the base member andextending in the machine direction from the base member to a distal endportion, the support member including a first surface and an opposingsecond surface, wherein the second surface of the support member facesthe first surface of the endless belt; a corona treater; and a pluralityof rollers, each roller having an outer circumferential surface andadapted to rotate about an axis of rotation extending in a crossdirection, wherein the rollers are spaced apart from each other alongthe machine direction with the outer circumferential surfaces adjacentthe first surface of the endless belt.